MC 60 NAVIGATION CONVERTER

MAINTENANCE MANUAL

2/24/99 8/31/09
1 2

TKM, INC.
14811 N. 73RD STREET
SCOTTSDALE, AZ 85260

PART # IMC60, REV. 2

August 31, 2009
 2

TABLE OF CONTENTS

Cover 1
Table of Contents 2
Introduction 3
Description 3
Specifications 4
Operation 4
Installation 6
Theory of Operation 7
Alignment and Test 9
Layouts, Schematics, and Parts Lists 11
Top Assembly (P/N AT6000) 12
Front Panel 18
Converter 25
VOR & LOC Demod 30
Glide Slope & GPS 36
Operating Controls 41
MC60 Interconnect 42
Channeling Codes 43
Mounting Dimensions 44
 3

INTRODUCTION
The purpose of this manual is to provide information of sufficient detail to permit repair
and alignment of the MC60 NAVIGATION CONVERTER. The MC60 contains a Field
Programmable Gate Array (FPGA) which contains most of the digital circuitry. This
manual defines the input - output characteristics of this array.

DESCRIPTION
The MC60 NAV Converter is a solid state device that converts and displays a variety of
navigation signals. All displays are LEDs and provide a high degree of reliability.
Deviation displays are bar graphs comprised of five yellow and five red dots.
Annunciation displays are individual LEDs and are color coded to reduce ambiguity.

The acceptable input signals include ARINC, ARC, and NARCO (Mark 12) for VOR and
Localizer; Glide Slope meter drivers, GPS meter drivers, and Marker Beacon lamp
drivers. Display selection is accommodated by grounding the appropriate enable lines.

The display, shown in Figure 1, includes Up, Down, Right, and Left bar graph; Glide
Slope (GS), Inner (I), Outer (O), Zonal (Z), To (T), From (F), and Track
(Trk).annunciation lights and a digital readout. The digital readout indicates Bearing in
degrees in the VOR mode, LOC in Localizer mode, bac for back course LOC, and GPS
for GPS.

Front panel controls include a MODE switch to toggle between ‘normal’ VOR and
Tracking operations, an RCP switch to toggle between TO and FROM operations, an
OBS control to select a bearing in the ‘normal’ VOR operation, a VOR centering control,
a LOC centering control, an LOC centering control, and a Dimmer adjustment. The
centering and dimmer controls are situated behind mounting screws and are normally
adjusted during installation.

An autopilot output is provided on the rear panel for Left-Right control.

 4

SPECIFICATIONS
NAV Signal Inputs: ARINC: 2.0 vpp (.5 vrms)
ARC 2.8 vpp (.7 vrms)
NARCO 12 vpp (2.9 vrms)

GPS Input: L/R: +/ - 150 uA FS into 1000 ohms

TO/FR: +/ -200 uA into 200 ohms
FLAG: 150 uA into 1000 ohms

GS Input: U / D: +/ -150 uA into 1000 ohms

FLAG: 150 uA into 1000 ohms

Autopilot Output: L / R: +/ -150 uA FS into 1000 ohms

Marker Beacon: Ground to activate (20 ma.)

Power Input: 10 to 30 vdc. 0.4 A

Weight: 1.3 lbs.

OPERATION
The operating controls and display are shown in Figure 1 page on 41.

VOR
VOR operation is available in two modes which can be selected by the ‘Mode’ button.
The tracking mode is indicated by the activation of the Trk light. The absence of the Trk
light and the display of a bearing in the digital display indicates the normal VOR
indicator operation.

In the tracking mode the left and right bar graphs are off. If a valid VOR signal is input,
the bearing to or from the station will be displayed and the Valid light will be on. To or
from selection is made by pressing the Rcp button. If a valid VOR signal is not present
the digital display will be three dashes.

In the normal mode the OBS will allow selection of the desired bearing. The Rcp button
is used to select to or from bearings. When a valid VOR signal is input, the Valid light
will be on and the left or right bar graph will indicate the deviation from the desired
bearing. The direction of correction is the same as the traditional fly-to–the needle
system; in this case fly-to–the-tip-of-the-bar-graph. Each dot of the bar graph represents
one degree bearing deviation.

Localizer
When a localizer channel is selected on the associated NAV receiver the digital display
will indicate ‘LOC’. If a valid signal is present the ‘To’ light and the ‘Valid’ light will be
 5

on. The bar graph indicates the direction and amount of correction required. The ‘Right’
bar graph indicates fly right and the ‘Left’ bar graph indicates fly left.

If back course localizer is selected (by external switching) the digital display will indicate
‘bac’ and the Left and Right bar graphs will be reversed.

GPS
If GPS is selected (by external switching) the digital display indicates ‘GPS’ and the
‘Valid’, ‘To’, and ‘From’ lights and the ‘Left’ and ‘Right’ bar graphs are under control of
the installed GPS unit.

Glide Slope
When a valid Glide Slope signal is input to the MC60 the ‘GS’ light is on and the vertical
bar graphs are activated. The ‘Up’ bar graph indicates fly up and the ‘Down’ bar graph
indicates fly down. The loss of a valid signal turns off the ‘GS’ light and the vertical bar
graphs.

Marker Beacon
The three Marker Beacon lights (I, O and Z) will be activated when the appropriate
control signals are input.

Dimming
Automatic dimming is included in the unit and adjustment of the dim level can be made
by removing the upper left mounting screw and with a 0.080 diameter jewelers screw
driver inserted in the hole set the desired dim level. The brightness level is not
adjustable.

INSTALLATION
Mechanical
The unit is intended for installation in the instrument panel. While the unit does not have
parallax error as is common with meter type displays it is still desirable to locate the unit
with a good viewing angle to get good display contrast and ease of pilot control.
 6

The outline dimensions and panel cutout is shown on page 44. Since the mounting holes
are used for system adjustments it is important to use the correct length screws. The
screws should not penetrate more than .25 inches into the front panel. 5/16 6-32 pan head
screws are recommended.

Electrical
An interconnect diagram is shown on page 42. As indicated, the Demod signal may be
derived from three different signal formats. The primary input is designed to interface
with the ARINC standard. A preamplifier is included in the MC60 to accommodate an
ARC level signal or a NARCO Mark 12 level.

The unit will operate with an A+ input of 12 to 28 vdc and has a current drain of 0.5 A
maximum.

Back course localizer is accommodated internally by grounding the BACK-EN line.

Auto pilot output is not affected by the BACK-EN so if it is necessary to provide back
course reversal for autopilot a polarity reversal relay must be added.

Marker beacon lights are activated by grounding the appropriate line. Maximum current
for each line is 20 ma.

Thermal
The MC60 does not require cooling for normal installations. However, particularly in 28
vdc installations with maximum deviation on both bar graphs in bright ambient light, it
may be necessary to add some convection cooling. The temperature of the rear panel of
the unit should not exceed 75 C.
Equipment Limitations
The following limitations indicate installation considerations in order for the MC60 to meet applicable TSO requirements.
1) The MC60 is intended for installation within a non-pressurized but controlled temperature location in aircraft operated
at altitudes up to 35,000 feet MSL.
2) The unit is intended for use in a standard humidity environment.
3) The unit is intended to be panel mounted in Single or Multi Engine Fixed Wing Aircraft with reciprocating or turboprop
engines.
4) The MC60 shall not be mounted less than .3 m from a magnetic compass.
5) The unit has not been tested with autopilots.
NOTICE TO INSTALLER
The TKM MC60 NAV CONVERTER AND INDICAOR is authorized by the FAA to TSO C34e, C36e, and C40c. The
product is an incomplete system. In order to achieve a complete TSO quality system, the MC60 must be installed to
configure in conjunction a TSO C37/C38 authorized antenna and a TSO C34 authorized navigation receiver. It is the
responsibility of the installer to ensure proper installation.
CONTINUED AIRWORTHINESS (HBA 98-18)
Permission is hereby given to installers approved by the recognized aviation authority to reference relevant excerpts from
the installation instructions provided by TKM, Inc. in order to fulfill documentation requirements for Instructions for
Continued airworthiness. Adequacy of the documents should not be assumed by this permission. Responsibility for ICA
documentation rests solely with the applicant. The MC60 product is ‘Repair on Condition Only’.

THEORY OF OPERATION
 7

The MC60 is built on three PC boards plus a display board. The description of operation
will be based on the operation of these three PC boards; the display board contains only
those circuits that are necessary to display and control operating conditions.

Glide slope and GPS Board (SS0604). The function of the Glide slope circuits is to
provide signals to the display board that simulate traditional meter movements. For
reference it should be noted that to designate a portion of an IC that has multiple sections
the sections are designated with letters with the first section being A and generally
includes pin #1 in its circuit; the sections increase alphabetically as the pin assignments
increase numerically.

U2/A is a differential amplifier which amplifies the Glide slope UP/Down signal. The
amplified signal is coupled to U2/B and U2/C which form an absolute value detector. The
signal is then coupled to U5 which is a bar graph generator. The bar graph generator
directly drives the Display LED's. Polarity sensing is accomplished by Q8 which is put
into cut-off when U2/B goes to ground. U6 controls the UP and Down drivers to activate
the proper Display bar.

U1/C and U1/D form a differential amplifier which detects the amplitude of the flag
current and activate the Glide slope LED when sufficient flag current is applied.

The GPS circuits perform essentially the same functions as the Glide slope circuits.
U3/C amplifies the LEFT-RIGHT signal; U3/D amplifies the flag signal; and U3/B
amplifies the TO-FROM signal. The TO-FROM signal is coupled to the VOR
Demodulator and LOC board and is selected for display when the GPS circuits are
activated.

The voltage regulator circuits are also on this board. Q4, 5 and 6 form a +9 volt regulator
and U4 is a +5 volt regulator.

The dimmer circuit consists of U1/A and U1/B. A 675 Hz square-wave (from the
Converter board) is formed into a trapezoidal signal by U1/A. The photocell on the front
panel controls threshold of the comparator U1/B to provide a variable duty cycle square
wave which is the used to control the on time of the anode drivers for the various
displays.

U3/A provides VOR/LOC signal pre-scaling and polarity change to accommodate

different Demod signal formats.

U2/D Provides a 0.170 Volt bias for the autopilot output circuit.

VOR Demodulator and LOC circuits (SS0603). The function of these circuits is extract
the 30 Hz Variable signal and 30 Hz Reference signal from the composite Demod signal
and to detect the amplitude of the 90 Hz and 150 Hz when operating in the LOC mode.
 8

U1/A is a 9960 Hz band pass filter. The filtered signal is demodulated in U9. The output
of U9 is filtered the 30 Hz band pass filter U2/C. U1/C forms a 30 Hz band pass filter
and is used to extract the 30 Hz Variable signal. The two 30 Hz signals are coupled to
the Converter board.

U3/A is a 90 Hz band pass filter. U3/B and C form a full wave detector. U4/A is a 150
Hz band pass filter. U4/B and C form a full wave detector. The two detected signals are
differentially amplified in U3/D and coupled to the autopilot output circuit U1/D and the
absolute value detector U2/A and B with switching circuits in portions of U6, U7 and
U8. Q1 senses polarity to activate the proper bar graph on the Display. U4/D senses the
amplitude sum of the two detected signals outputs a flag signal when the amplitude sum
is above the threshold level.

Portions of U5 and U6 form polarity reversal circuits for the Localizer signal when the
Back Course selection is activated.

Converter Board (SS0601). The 30 Hz Variable and 30 Hz Reference signals are input
to the Converter board. U17/A is a zero crossing detector for the 30 Hz Variable signal
and U17/B is the amplitude detector for the same signal. Similarly U17/C is the zero
crossing detector for 30 Hz Reference and U17/D is the amplitude detector.

U13 contains a VCO operating at 10800 Hz. The 10800 Hz is coupled to U12 and
divided by 360. The resulting 30 Hz signal is returned to U13 and Phase locked. U15/C
is used as an active loop filter for the phase lock loop.

U12 is a Field Programmable Gate Array (FPGA) and contains the circuitry required to
convert the Optical Encoder inputs from the Display board to bearing information and
provide multiplexed outputs for the Display digits. Also contained in U12 are phase shift
circuits, delay counters and signal switching logic. The configuration of the FPGA is
controlled by PROM U11. Configuration information is coupled to the FPGA whenever
power is applied. U10 is a seven segment decoder which works in conjunction with U12
to operate the Display digits.

U16/A and U16/B form a low pass filter to derive the TO-FROM signal from the phase
detection circuits in the FPGA. U16/C is a comparator which provides 0 or 5 vdc for TO-
FROM display control. U16/D provides a 2.50 VDC bias voltage.

U15/A, U15/B, abd U15/D form a low pass filter to derive the LEFT-RIGHT signal from
the phase detection circuits in the FPGA.
U14 is a bar graph generator and drives the LEFT-RIGHT bar graph on the Display
board.
ALIGNMENT AND FINAL TEST
The following operations are required for alignment and final test for the MC60.

Test equipment required:

FLUKE 75 Voltmeter or equivalent.
 9

TEKTRONIX TDS 210 Oscilloscope, or equivalent.

Low voltage dc supply to simulate Glide slope and GPS inputs
VOR/LOC composite signal source.

1.0) Verify proper regulator performance. Monitor collector tab of Q4. Voltage shall be
9.00 +/- .30 vdc for supply voltages of 10.0 to 35.0 vdc. Monitor pin 14 of U6 on
SS0604. Voltage shall be 5.00 +/- .20 vdc.

2.0) Apply -150 to +150 mV to Pin 2 and +300 mV on pin 3 and ground on pin 16 and
pin 15 of P1 on the Rear Panel. Adjust R36 on SS0604 to obtain - 10 dots to
+10dots on the UP-DOWN display; the GS LED should be ON. Reduce the
voltage on pin 3 to 100mv; the GS LED and bar graph should go off.

3.0) Apply -150 to +150 mV to Pin 24 and +300 mV on pin 12 and ground on pin 11,
pin13, pin 23 and pin 25 of P1 on the Rear Panel. The LEFT-RIGHT deflection
shall be -9 to-11 dots to +9 to +11 dots on the display; the center LED should be
ON. Reduce the voltage on pin 12 to 100mv; the center LED should go off.
Apply +50 to -50 mV on pin 10 of P1; The TO-FROM LED's shall switch from
TO to FROM. Remove ground from pin 13 of P1 to deactivate GPS.

4.0) Rotate the Dimmer adjustment to full CW and verify dimmer operation.

5.0) Alternately ground pins 5, 17 and 18 to verify proper Marker LED operation.

6.0) Apply a 0 degree composite VOR signal with the appropriate format to match the
input configuration as indicated on the Installation Drawings. Pin 14 of P2 on
SS0603 should be a composite signal of 2.00 +/- .20 volts P-P.

7.0) Steps in 7.X are performed on SS0603.

7.1) Monitor Pin 1 of U1. Adjust R31 for 3.5 volts P-P and R42 for balanced amplitude
peaks on the 9960 Hz signal.

7.2) Monitor Pin 8 of U1. Adjust R29 for 4.0 volts P-P and R40 for a peak output of
the 30 HZ Variable signal.

7.3) Monitor Pin 9 of U9. Adjust R63 for a 30 Hz signal centered at 3.3 vdc.

7.4) Monitor Pin 8 of U2. Adjust R28 for 4.0 volts P-P and R39 for a peak output of the
30 HZ Reference signal.

8.0) Monitor Pin 8 of U17 on SS0601. Adjust the VOR-Zero on the Display board to
obtain a 50% duty cycle square wave.

9.0) Monitor Pin 9 of U13 on SS0601. Adjust R40 on SS0601 to obtain 2.50 +/- .20
vdc.
 10

10.0) Adjust R40 on SS0603 for a centered LEFT-RIGHT bar graph.

11.0) Apply a 10 degree VOR error signal and adjust R52 on SS0601 for 10 dot
deflection.

12.0) Steps in 12.X are performed on SS0603.

12.1) Ground Pin 19 of P! on Rear Panel to activate LOC operation. Apply a centered
LOC signal with proper format . Monitor Pin 8 of U3. Adjust R38 for a peak of
the full wave rectified 90 Hz signal. Adjust R27 for 3.8 volts peak.

12.2) Monitor Pin 8 of U4. Adjust R41 for a peak of the full wave rectified 150 Hz
signal. Adjust R30 for 3.8 volts peak.

12.3) Apply a LOC signal with .094 DDM error and adjust R27 and R30 to obtain 6 dots
LEFT and 6 dots RIGHT deviation as the polarity of the LOC error is reversed.
The center LED shall be activated. Apply a centered LOC signal and delete the 90
Hz signal; the center LED shall deactivate. Delete the 150 Hz signal and center
LED shall deactivate.

12.4) Ground Pin 6 of P1 on the Rear Panel and verify that the LEFT-RIGHT deflection
is reversed.

13.0) Place MC60 in oven at +65 C degrees for 20 minutes.

14.0) Remove MC60 from oven and run on test bench. Verify the unit displays normally
and at low level signal inputs (to 107 db).

LAYOUTS, SCHEMATICS, AND PARTS LISTS

INDENTURED DRAWING LIST

 11

MODEL MC60
AT6000 REV NONE MC60 TOP ASSEMBLY
HM0601 NONE BAR, SIDE
SM0606 REV 6 PANEL, REAR: MC60
HM0605 NONE HEAT SINK
SM0607 NONE COVER
MP0600 REV 2 TSO NAMEPLATE: MC60
SS0605 REV 1 FRONT PANEL; MC60
HM1905 REV 4 FRONT PANEL; MC60
PL0603 NONE DISPLAY FILTER; MC60
PL0602 NONE DISPLAY MASK; MC60
SS0602 REV 4 FNT PANEL SUBASSEMBLY; MC60
SS0601 REV 7 CONVERTER; MC60
SS0603 REV 6 VOR & LOC DEMOD; MC60
SS0604 REV 7 GLIDE SLOPE & GPS; MC60
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45